Method for manufacturing pegboard hooks

ABSTRACT

The invention relates to a method of manufacturing new peg board display hook. The new hook is characterized particularly by the construction of its principal components, a base member and a hook member, and the manner in which these two components are secured together. The base member is stamped and formed of sheet or strip metal stock to provide a cylindrical walled opening. The base member is given a surface plating treatment subsequent to its formation but prior to assembly with the hook member. The hook member is formed of pre-plated wire stock, which is cut to length, shouldered and headed, and then inserted into the walled opening of the base member. The base and hook members are then locked together by mechanical deformation of one or both parts. The new constructional technique enables extra-ordinary reductions in manufacturing cost to be realized while, at the same time, providing an end product which is actually far superior to the conventional product.

United States Patent 1191 Thalenfeld 11] 3,815,198 v1451 June 11, 1974 METHOD FOR MANUFACTURING PEGBOARD HOOKS Inventor: David R. Thalenfeld, 164-41 Powells Cove B1vd., Beachurst, N.Y. 11357 Filed: Dec. 27, 1972 Appl. No.: 319,041

Related US. Application Data Division of Ser. No. 62,271, Aug. 10, 1970, Pat. No. 3,724,792.

us. c1 29/150, 29/417, 248/223 1111. c1 823p 13/00, B23p 17/00 Field of Search 29/150, 417; 248/223;

[56] References Cited UNITED STATES PATENTS 1/1966 Turner 29/150 X 8/1972 Worley 29/150 X Primary Examiner-Thomas H. Eager Attorney, Agent, or Firm-Mandeville and Schweitzer [57] ABSTRACT The invention relates to a method of manufacturing new peg board display hook. The new hook is characterized particularly by the construction of its principal components, a base member and a hook member, and the manner in which these two components are secured together. The base member is stamped and formed of sheet or strip metal stock to providea cylin- The new constructional technique enables extra-ordinary reductions in manufacturing cost to be realized while, at the same time, providing an end product which is actually far superior to the conventional product.

8 Claims, 7 Drawing Figures -7 o I i i 24 iii i l Ill Ill 3 PATENTEDJHN v 1 1914 3.815; 198

24 24 32 I I I7 I. 244. u 23 v 7; I: 7 v GCE in m METHOD FOR MANUFACTURING PEGBOARD HOOKS This is a division, of application Ser. No. 062,271, filed 8/10/70, now U.S. Pat. No. 3,724,792, issued Apr. 3, 1973.

BACKGROUND AND SUMMARY OF INVENTION The present invention is directed to a method for making peg board display hooks. In general, these hooks comprise a base of suitable construction provided with a pair (typically) in an upturned lugs adapted to be inserted in spaced openings inlan apertured display board, frequently referred to as peg board. A suitable hook member is carried by the base member and extends outward from the display board for the support of display articles, most frequently carded merchandise. There are several principal types peg board hook devices in active commercial use at the present time. One such principal type, with which the present invention is primarily concerned, comprisesa base member formed of sheet metal and a hook member formed of wire stock. The E.M. Levy U.S. Pat. No. 2,926,877, the E.M. Levy et al. U.S. Pat. No. 2,810,539, and the Mapson U.S. Pat. No. 2,614,701 are representative of peg board display hook devices of this general type.

In the construction of peg board hooks of the type comprising a sheetmetal base member and a wire hook member, it has been conventional, at least among the constructions which have achieved a degree of commercial success, to secure the wire-like hook portion to the sheet metal base portion by welding techniques, usually electric resistance welding. Efforts to provide more simple, mechanical assembly of the parts have i been unsuccessful for a variety of reasons related primarily to an inability to achieve adquate strength in assembled joints. Devices assembled by welding techniques have a number of disadvantages, including extra production costs occasioned by the large number of part and product handling operations, and also by the fact that the welded joints are often defective. Nevertheless, this appears to be the only construction which has achieved any degree of commercial success.

It is a basic objective of the present invention to provide a completely new approach to the construction and manufacture of the plate and wire type of peg board, hook, utilizing entirely mechanical assembly of the parts, which may be manufactured at a substantial reduction in cost relative to the conventional, welded unit, and which at the same time provides a significantly superior product, having superior features anda plate-to-wire joint of superior strength. The advantages of this invention are realized in part by incorporation in a new hook of a novel plate-to-wire joint structure which is produced solely by mechanical manipulations capable of being carried out at extremely low cost on high production machinery and, at the same time, providing a joint of exceptional strength. Additional significant advantages of the invention are derived from so carrying out the manufacturing operation that plating of the device (required by standards of commercial acceptance) is carried out prior to final assembly, rather than subsequent thereto, saving many handling operations and significantly reducing the overall cost of production.

For a better understanding of the invention, reference should be made to following detailed description and to the accompanying drawing.

DESCRIPTION OF THE DRAWING FIG. I is a perspective view of a peg board display hook constructed in accordance with principals of the invention.

FIG. 2 is a greatly enlarged, fragmentary cross sectional view taken generall along line 22 of FIG. I.

FIG. 3 is an enlarged, fragmentary back elevational view of the device of FIG. 1.

FIG. 4 is a planned view of a section of metal strip undergoing a progressive cutting and forming operations in the production of sheet metal base members to be incorporated in a device of FIG. 1.

FIGS. 5 & 6 are elevational views of a section of wire, before and after the carrying out of certain forming operations thereon in preparation for assembling with a base plate member to form a deviceof FIG. 1.

FIG. 7 is an enlarged fragmentary cross sectional view taken along line 77 of FIG. 3.

DESCRIPTION OF A PREFERRED EMBODIMENT OF THE INVENTION Referring now to the drawing, the reference numerals 10, 11 designate generally the hook and base members respectively of the peg board hook of the invention. In a typical construction, the hook 10 is provided at its outer end with an upturned tip portion 12 having a balled enlargement 13 at its extremity. Adjacent its inner end, the hook member 10 has a shoulder enlargement 14 and a mounting extention 15. The base member 11, of sheet metal construction, comprises a flat plate section 16 having lugs l7, 18 at each of its upper corner regions. The lugs l7, 18 extend rearward and upward and are adapted to be received in adjacent openings in an apertured display board in the conventional manner. In its center area, the base member 11 is provided with a forwardly projecting boss 19 surrounding a center opening 20 in which the mounting extention I5 is received.

In accordance with the invention, the assembled joint, connecting the wire and base members 10, 11, is exclusively a mechanical joint. To this end, both of the hook and base members incorporate unique features of construction to be described in greater detail.

Referring now to FIG. 4, there is illustrated a sequence of production operations, advantageously carried out on a progressive die cutting and forming production machine, to bring about the conversion of metal strip or sheet stock into individual base members 11 incorporating the unique features of the invention. Thus, the reference numeral 21 designates the raw strip stock constituting the infeed to the machine. For a typical small size peg board hook, the strip stock 21 may comprise a steel strip having a width on the order of 3 inches and a thickness of about 0.060 inches, it being understood, of course, that the specific demensions referred to herein are intended as an aid to the complete understanding of the invention and not as implying any limitation thereto.

In passing through the machine the strip stock 21 is cut and formed to produce, at the discharge end side by side pairs of base members 11, as reflected at the right hand side of FIG. 4. In the first stage of the progressive cutting and forming machine, the strip stock is punched to provide locating holes 22. In the second 5 In the third stage of the forming machine, center openings 27 are formed in the boss indentations 23, intended for the eventual reception of the inner end extentions of the hook members. In accordance with the invention, however, the initial center opening 27 is grossly undersize relative to the diameter of the hook extention 15. By way of example, where the hook and extention 15 has a diamenter of about 0.164 inches, the initial or pre-piercing diameter of the opening 27 advantageously is on the order of 0.120 inch.

In the fourth production stage of the strip stock 21, the openings 27 are enlarged and extruded by passage therethrough from the front to the back of a piercing element (not shown but conventional in metal forming work). The piercing element typically is in the form of a tapered rod, the small end of which is readily receivable within the initial opening 27 and the larger diameter of which is of substantially greater size than the opening 27. The piercing element operates in conjunction witha suitable die, alsoconventional in itself, to effect as it passes through the opening 27, a rearward extrusion of the sheet metal surrounding the opening 27, providing a rearwardly extending cylindrical wall 28, as shown in FIG. 2. Advantageously, the punching operation performed on the opening 27 is calculated to produce for the typical article mentioned above, a cylindrical opening 29 having an internal diameter on the order of 0.155 inch. This is designed for the reception with an interference fit of a hook member extention whose diameter is on the order of 0.164 inch. Typically, the depth of the extruded side wall 28, measuring from the front surface 26 to the back surface 30 may be on the order of 0.010 inch. As will be observed in FIG. 2,the rear surface 30 of the extruded side wall 28 terminates well forward of the rear surface 31 of the base member, providing a small clearance space for the accommodation of the end extremity of the hook member 10 as will be further described.

As an additional operation in the fourth forming stage of the strip stock 21, sections of the metal containing the locating openings 22 are punched out, leaving lug, strips 32. The removal of the locating holes 22 at this stage does not affect the precision manipulation of the strip stock, as the, openings remain in the three previous stages.

In the fifth formation stage, the lug strips 32 are provided with strengthening grooves 33, which advantageously extend somewhat into the flat type section 16. At the same time, the end surface 30 of the extruded cylindrical wall 28 is acted upon by a suitable deforming die to form three radial indentations in the side wall, advantageously spaced apart at approximately 120. The indentations, designated by the numeral 34 in FIG. 4 advantageously have a width, measured circumferentially of the side wall, of on the order of 0.040 inch. The indentations may have a maximum depth of around 0.030 inch and are slanted somewhat downward and inward. The deformation of metal resulting from the forming of the indentations 34 advantageously forces small key like segments of metal 35 into the walled opening 29, as shown in FIG. 7.

In the sixth forming station, the lug strips 32 are bent rearward and upward, to form the finished lugs 17, 18, and in the seventh forming station a separation opening 36 is provided between adjacent base members emerging towards the discharge end of the machine. In the eighth station, the base members are completely separated by removal of the remaining segment of connecting metal in the comer area 37, and the individual finished base members 11 are discharged from the machine.

In accordance with one aspect of the invention, the completely formed base members 11, prior to assembly with hook members 10, are given a protective surface covering, as by galvanizing, cadmium plating, etc. The plating serves both to improve the appearance of the element and also to protect it against oxidation. For convenience of reference, the base elements, being surface protected at thisstage of the manufacturing process, are referred to as being post-plated, this term as being used herein clearly excluding, however, base elements which are plated subsequent to their assembly with hook members.

In accordance with another aspect of the invention, I

the wire'stock 40 used in the production of hook members 10 for the device of the invention is surface protected while still in its bulk wire form and prior to its being severed into invidual sections in the production of hook members. For convenience of reference, the wire stock incorporated in the device of the invention may be described as being pre-plated. Most advantageously, the wire is a relatively hard steel wire surface treated prior to cutting by being electro-galvanized and polished.

In the manufacturing procedure according to the invention, the wire stock 40 for a typical small size peg board hook assembly may have a basic diameter of around 0.147 inch. Thiswire is fed into a suitable multiple stage production forming machine (in itself constituting no part of the invention) where the wire is shaped and assembled with the base member 11. In a typical production sequence, the wire stock is fed into the machine and, in a first forming stage, the wire stock is severed to the desired length and shaped to provide a shoulder enlargement 14 and an end extention 15. For the above described hook assembly, the extention 15 may have an axial length of around 0.120 inch and a diameter of around 0.164 inch, and the shoulder 14 may have a diameter of around 0.210 inch.

In a second production stage, the wire 40 is acted upon by appropriate dies to form a balled enlargement 13 at the outer end extremity of the wire. The formation of the balled enlargement 13 is of particular advantage in the hook assembly of the invention, because of the pre-plated outer surface of the wire stock 40 is deformed to partially close over the cut outer end extremity 41 of the-wire, which otherwise would, expose the bare metal of the wire stock.

In a third production stage, the partially formed wire, substantially as reflected in FIG. 6, is forcibly inserted in the base member opening 29, and the projecting end portion 42 (FIG. 2) of the wire extention 15 is acted upon by an appropriate staking die to provide three angularly spaced deformations 43 in the wire end extention 15. The deformations 43 act in conjunction with the shouldered enlargement 14 to rigidly lock the wire into the base element 11. Moreover, the three deformations 43 are aligned with the corresponding deformations 34 in the side wall 28 of the base element opening to provide a rigid mechanical interlock against rotary displacement of the hook element relative to the base element. ln this respect, it has been found that three equi-angularly spaced deformations constitutes an optimum number and orientation for locking the wire against rotation. A lesser number is inefficient, while a greater number tends to increase the overall roundness" of the interlocking area and may actually reduce the strength of the interlock. ln this respect, resistance of the assembled unit to rotary displacement is particularly important for commercial acceptance. For example, certain of the commercial tests to which peg board hook assemblies are subjected involve bending of the wire element atright angles to the axis of its inner end extremity to provide great leverage, and then attempting to rotate the wire relative to the base element to which it is attached. The peg board hook assembly of the present invention exhibits superior antirotational strength when subjected to such testing procedures.

In a typical production sequence, after assembly of the wire element toa previously manufactured base element 11, the wire is acted upon by appropriate dies to form the upturned tip portion 12, and also to tilt the wire slightly upward adjacent the inner end to impart a few degrees of upward incline to the hook portion 10 in the completed unit. It is also practical, during this sequence, to impart special shapes and bends to the wire tip, to meet individual customer requirements. The new procedure permits this to be carried out at practically no extra production cost, whereas conventional procedures typically require a substantial upcharge for special tip configurations.

Significant overall advantages are realized in the production' of peg board hooks in accordance with the invention in that a unit of superior quality is produced at a significant reduction in production cost relative to the conventional hook. The design of the hook is such that it may be produced entirely by mechanical operations performed on high speed, multi-stage cutting and forming machines which are commercially available, so that there is minimum individual handling of the components. Further, rather than following the conventional procedure of plating the units after assembly, the improved hook of the invention utilizes post-plated base members and pr'e-plated hook members, such that the mechanically assembled unit incorporates the desired surface finish as it emerges from the assembly machine. In this respect, although the base members 11 are subjected to plating or other suitable finishing operations after forming, it is possible to carry out the finishing operations at this stage with the base elements in a bulk form, without requiring individual handling, counting, etc., as is the case with pre-assembled units. This enables significant savings in labor cost to be realized. In a commercially feasible plate and wire style of peg board hook of conventional construction, the surface finishing operation is required to be performed after assembly has been completed because, heretofore, commercially acceptable units were required to be welded at the plate-to-wire joint, and the welding operation would of course damage any previously imparted finish.

LII

The many advantages of the present invention are enabled to be realized by reason of the unique mechanical joint by which the wire hook member 10 may be joined to the plate-like base member with a strength and rigidity acceptable to the large volume commercial users of peg board hook units of this type (e.g., super markets, variety stores, discount stores, etc.). In part, the exceptional strength of the joint is derived by the formation of the walled opening 29, resulting from pre-piercing of the base member to a relatively small diameter opening and subsequently enlarging the opening and extruding the material surrounding it in a axial direction to form an extended cylindrical sidewall 28. This extended sidewall, in conjunction with a shouldered enlargement formed on the wire element and bearing against one side of the base member 11, and radial deformations 43 bearing against the cylindrical wall 28 on the opposite side of the base member, provides a joint of extraordinary strength, which is not only superior to the conventional welded joint but does not involve the significant factor of unreliability which is experienced with the welded joint.

While providing significant economies in the manufacture of peg board hooks, the hook of the present invention provides a feature which is conventionally available only as an extra," at an additional cost. Thus, with hooks of conventional construction, the outer end portions of the hook element typically are simply cut off square. Where a balled enlargement is desired at the end, as a safety feature or for improved appearance, it is customarily available only at a substantial upcharge of around 0.5 to 0.7 cents per unit. In the hook of the present invention, the raw wire stock 40 is in any event travelling through a multi-stage forming machine, so that the balled enlargement 13 can be provided for virtually no additional cost, apart from the minor investment in the die in the first instance. The balled enlargement 13 of the present hook assembly performs an additional function, of course, in that it closes the plated outer surface of the wire substantially over the end thereof, largely concealing the raw metal otherwise exposed by the cutting of the wire to length. This obviates the needfor plating or other surface treating of the unit after assembly, resulting in major reductions in handling costs.

It should be understood, of course, that this specific form of the invention herein illustrated and described is intended to be representative only, as certain changes may be made therein without departing from the clear teachings of the disclosure. Accordingly, reference should be made to the following appended claims in determining the fullscope of. the invention.

1 claim:

1. The method of making a peg board hook or the like, which comprises a. cutting-and stamping a section of sheet metal to form a flat base member having an opening therein for the reception of a hook member and lugs for engagement with openings of a display board;

b. forming a forwardly projecting boss on said base member in the region of and surrounding said opening;

c. initially forming said opening to a diameter substantially less than that of the hook member and thereafter enlarging said opening and forming a rearwardly extending cylindrical side wall by pass- 7 ing a tapered punch through the opening from front to back;

d. forming a hook member to have a cylindrical inner end portion of larger diameter than that of the enlarged opening;

e. forcibly inserting the hook member into the enlarged opening, and

f. mechanically deforming selectively either the said hook member end portion or said cylindrical side wall or both to interlockingly engage said base and hook members.

2. The method of claim 1, further characterized by a. plating .said base member after the cutting and stamping thereof,

b. plating said hook member prior to the forming thereof.

3. The method of claim 2, further characterized by a. said hook member being formed of pre-plated wire stock,

b. said wire stock being cut to length and balled at its outer end to partially enclose said outer end with pre-plated surface.

4. The method of claim 3, further characterized by a. said wire stock further being deformed adjacent its inner end to provide a shoulder for seating against the front face of said base member.

5. The method of making a pegboard or the like which comprises 7 a. forming a base member of post-plated sheet metal b. forming a hook member of pre-plated wire, c. mechanically interlocking said base and hook r 8 members by forcebly inserting the hook member into a walled opening in the base member and deforming one or both of the base member or hook member.

6. The method of claim 5, further characterized by a. forming the walled opening in the base member by first cutting a grossly undersize opening therein and thereafter forcing a punch through the opening from front to back to enlarge its diameter and deform inwardly surrounding portions of that metal to form a cylindrical wall.

7. The method of claim 6, further characterized by a. said hook member being formed by cutting to length said pre-plated wire and forming a ball-like enlargement at the outer end extremity and an annular shoulder enlargement adjacent but spaced from its inner end;

b. said shoulder being caused to be seated tightly against the front face of said base member.

8. The method of claim 7, further characterized by a. the cylindrical wall of said base member being deformed at its inner end at three angularly spaced points to provide sharp indentation in the inner end face of said wall and to provide projections of deformed metal extending radially inward from said wall, and

b. deforming the inner end extremity of said hook member after insertion in said walled opening at three angularly spaced points coinciding and interlocking with said indentations. 

1. The method of making a peg board hook or the like, which comprises a. cutting and stamping a section of sheet metal to form a flat base member having an opening therein for the reception of a hook member and lugs for engagement with openings of a display board; b. forming a forwardly projecting boss on said base member in the region of and surrounding said opening; c. initially forming said opening to a diameter substantially less than that of the hook member and thereafter enlarging said opening and forming a rearwardly extending cylindrical side wall by passing a tapered punch through the opening from front to back; d. forming a hook member to have a cylindrical inner end portion of larger diameter than that of the enlarged opening; e. forcibly inserting the hook member into the enlarged opening, and f. mechanically deforming selectively either the said hook member end portion or said cylindrical side wall or both to interlockingly engage said base and hook members.
 2. The method of claim 1, further characterized by a. plating said base member after the cutting and stamping thereof, b. plating said hook member prior to the forming thereof.
 3. The method of claim 2, further characterized by a. said hook member being formed of pre-plated wire stock, b. said wire stock being cut to length and balled at its outer end to partially enclose said outer end with pre-plated surface.
 4. The method of claim 3, further characterized by a. said wire stock further being deformed adjacent its inner end to provide a shoulder for seating against the front face of said base member.
 5. The method of making a pegboard or the like which comprises a. forming a base member of post-plated sheet metal b. forming a hook member of pre-plated wire, c. mechanically interlocking said base and hook members by forcebly inserting the hook member into a walled opening in the base member and deforming one or both of the base member or hook member.
 6. The method of claim 5, further characterized by a. forming the walled opening in the base member by first cutting a grossly undersize opening therein and thereafter forcing a punch through the opening from front to back to enlarge its diameter and deform inwardly surrounding portions of that metal to form a cylindrical wall.
 7. The method of claim 6, further characterized by a. said hook member being formed by cutting to length said pre-plated wire and forming a ball-like enlargement at the outer end extremity and an annular shoulder enlargement adjacent but spaced from its inner end; b. said shoulder being caused to be seated tighTly against the front face of said base member.
 8. The method of claim 7, further characterized by a. the cylindrical wall of said base member being deformed at its inner end at three angularly spaced points to provide sharp indentation in the inner end face of said wall and to provide projections of deformed metal extending radially inward from said wall, and b. deforming the inner end extremity of said hook member after insertion in said walled opening at three angularly spaced points coinciding and interlocking with said indentations. 